Advancing Sustainable Materials Engineering with Natural-Fiber Biocomposites

Natural-fiber biocomposites are increasingly viewed as promising materials for sustainable engineering. However, their broader adoption remains constrained by coupled challenges related to interfacial compatibility, moisture sensitivity, environmental durability, processing limitations, and end-of-life trade-offs. Rather than treating fiber selection, matrix chemistry, processing routes, durability, and sustainability as independent considerations, this review emphasizes their interdependence through the fiber–matrix interface, which governs stress transfer, moisture transport, and long-term property evolution. It provides a comprehensive and integrative analysis of natural-fiber–reinforced polymer composites, encompassing plant-, animal-, and emerging bio-derived reinforcements combined with bio-based, biodegradable, and selected synthetic matrices. Comparative analysis across the literature demonstrates that interfacial engineering consistently dominates mechanical performance, moisture resistance, and property retention, while mediating trade-offs among stiffness, toughness, recyclability, and biodegradability. Moisture transport and environmental ageing are examined using thermodynamic and diffusion-controlled frameworks that link fiber chemistry, interfacial energetics, swelling, and debonding to performance degradation. Fire behavior and flame-retardant strategies are reviewed with attention to heat-release control and their implications for durability and circularity. Processing routes, including extrusion, injection molding, compression molding, resin transfer molding, and additive manufacturing, are assessed with respect to fiber dispersion, thermal stability, scalability, and compatibility with bio-based systems. By integrating structure–property relationships, processing science, durability mechanisms, and sustainability considerations, this review clarifies how natural-fiber biocomposites can be designed to achieve balanced performance, environmental stability, and circular life-cycle behavior, thereby providing guidance for the development of systems suitable for near-term engineering applications.